JP3333497B2 - Friction welding method and friction welding device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a rotation tool - related to friction welding method utilizing plastic flow frictional heat Le and workpiece,
It can be used for all structures such as vehicles, automobiles, ships, aviation, elevators, pressure vessels and the like.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. 5-963 discloses a friction welding method.
No. 85 is known. Conventional friction welding methods rotate the workpiece to be welded or both. For this reason, there are limitations on the shape and dimensions of the workpiece to be welded.

On the other hand, as a method for continuously friction welding in the longitudinal direction of a work, Japanese Patent Application Laid-Open No. 7-505090 discloses a method of working a tool made of a material substantially harder than a work. 2. Description of the Related Art There is known a welding method in which a workpiece is welded by being inserted into a welded portion of a workpiece and moving while rotating the tool, so that plastic flow due to frictional heat generated between the rotating tool and the workpiece. It is.

In the conventional friction welding method, the workpieces are rotated and the workpieces are welded by frictional heat. On the other hand, Japanese Patent Publication No. 7-505090 discloses a method in which a welding member is fixed. The joining can be performed by moving the tool while rotating it. Therefore, there is an advantage that even a member that is substantially infinitely long in the welding direction can be continuously solid-phase bonded in the longitudinal direction. Furthermore, since solid-state welding is performed using plastic flow of metal due to frictional heat between the rotary tool and the welding member, the joining can be performed without melting the joint. Also,
Since the heating temperature is low, deformation after bonding is small. Since the joint is not melted, there are many advantages, such as fewer defects.

[0005]

Problems to be Solved by the Invention, Japanese Patent Application Laid-Open No. 7-50 / 1990
Rotation tool according 5090 JP - Le inserted into the workpiece, 該回 Utatetsu - when applying the method of welding by moving while rotating the Le in the product, have the following problems.

[0006] Some reasons for the welds by the above welding method
When a defect occurs in a structure, when it is applied to a structure, there is a problem in reliability.

[0007] The present invention repairs the defect, and again friction welding
The aim is to provide a method that can.

( 3 ) The thickness of the joint is locally reduced by the cutting action of the rotary tool. That is, the surface of the welded portion is dented due to friction with the rotating tool.
For this reason, since the thickness of the joint is substantially reduced, the strength of the weld is reduced. Therefore, there is a problem in the reliability of the workpiece joined by this welding method.

( 4 ) If there is a gap in the joint at the joint, a defect is likely to occur.

[0010]

SUMMARY OF THE INVENTION The present invention relates to a friction welding method.
Cutting a defect generated in the welded part of the work
The cavity containing, by inserting the insertion member of the cavity portion substantially the same shape, in front of the rotary tool, the insert member
With the roller pressed,
Therefore, the insertion member is friction-welded.
You.

[0011]

[0012]

[0013]

[Action] (1) Defects formed in the welded part of the workpiece by friction welding
Is cut into a cavity including the cut portion, substantially with the cavity.
Inserting an insertion member having the same shape
And weld again from behind. As a result, the defect is completely replenished by the insertion member, resulting in a sound weld. In this case, since the insertion member may move in the traveling direction due to the force of the rotary tool during welding, the front of the rotary tool is pressed by a roller .

[0015]

[0016]

[0017]

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference Example 1 FIG. 1 is a perspective view of a case where a workpiece 4 is welded by moving a rotary tool 1 in a direction 3 while rotating a rotary tool 1 in a direction 2 by the welding method. The figure is shown. FIG. 2 is a cross-sectional view illustrating an example of a welding defect generated in the welded portion 5 of FIG.

FIG. 3A is a cross section taken along the line AA in FIG.
The defect 6 in this case is likely to occur at the end of the weld or at the position where welding is stopped. The shape of the defect 6 is a cavity having substantially the same shape as the tip of the rotating tool. (B) is a cross section taken along the line BB, and the defect 7 in this case is likely to occur when welding conditions are not appropriate. This defect 7 occurs almost continuously from the welding start point to the end of welding, and can often be visually observed from the surface of the welded portion. (C) is a cross section taken along the line CC, and the defect 8 in this case is also a defect that occurs when welding conditions are inappropriate. The defect 8 often occurs discontinuously inside the weld.

In this apparatus, a member having the same shape as each of the above-mentioned defects is inserted into each of the defective portions shown in FIG.
I do . Next, this will be described specifically. Since the defect 6 in FIG. 3A is a columnar cavity, a member 9a having the same shape is inserted into the cavity. Since the defect 7 in (b) is a rectangular elongated cavity, a part of the defect is processed, and a member 9b having substantially the same shape as this is inserted. In this case, since the inserted member is long, this member is fixed to the processed member by the TIG welding method.

Since the defect 8 in (c) is generated inside the welded portion, it is mechanically cut from the front surface or the back surface of the welded portion to the position of the defect, and the hollow portion including the cut portion is cut into the hollow portion. A member 9c having the same shape as the above is inserted.

As described above, after a member having the same shape as each defect is inserted into each defective portion (hollow portion), welding is performed again from the rear side of the position where the member is inserted by the above-described welding method.

The member to be inserted into the defective portion is desirably the same material as the processed member.

The length of the aluminum alloy in this reference example is 5
m, thickness: 4 mm, width: 0.5 m, and welding conditions were as follows: tip diameter of rotary tool: 5 mm, number of rotations: 1000 rpm, welding speed: 0.2 m / min. By the above method, a highly reliable welded portion was obtained, and this was applied to welding of railway vehicles.

Embodiment 1 FIG. 4 is a perspective view showing a method of fixing an insertion member by a roller mechanism.

The present invention is for mechanically fixing the member 9 inserted into the defective portion by the roller 10. That is, when the defect is long in the welding direction, the insertion member 9 is pressed against the processing member 4 by the roller 10 in front of the rotary tool 1 with respect to the welding direction. As a result, the insertion member 9 is fixed immediately before the rotary tool 1. In addition,
The rail 10 moves in the welding traveling direction 3 in conjunction with the rotary tool 1.

On the other hand, the roller 10 can move up and down independently of the rotary tool 1 to follow the deformation of the processing member 4.
There is one. The pressing force of the roller in this case is about 500 kg. The welding conditions and the dimensions of the processed members are those of Reference Example 1.

Reference Example 2 FIG. 5 shows a face plate 12 and a core manufactured by extrusion.
In joining the honeycomb panels made of the material 13, the rotary tool 1 is inserted into the edge material 14 and welded. Thus, a large honeycomb structure is manufactured by combining a plurality of honeycomb panels. In the present reference example, the thickness of the edge material of the welded portion where the rotary tool 1 contacts is increased by 1 mm. The width is 20 mm, which is almost the same as the outer shape of the rotary tool. Due to the shape of the welded portion, the strength is not substantially reduced even when the rotary tool 1 causes the joint to be dented. Furthermore, even if the gap at the joint is large, joining can be performed without defects. For this reason, a structure made of a highly reliable honeycomb panel can be manufactured efficiently and at low cost.
A high-speed vehicle was manufactured using this honeycomb panel as a railway vehicle body.

[0029] [Reference Example 3] FIG. 6 shows the joint structure of the joint. (A)-(b) of FIG.
(C) and (d) show the joint structure in which the processing member 4 has an I-shaped groove.
(E) and (f) show joint structures of a V-groove. As shown in FIG. 6, by locally increasing the thickness of the welded portion, in the case of an I-shaped groove, welding can be performed without defects even when the gap is large.

[0030] In this reference example, when the thickness of the workpiece is welded to 5mm aluminum alloy I die opening destination (a), the gap of the groove can be welded without defects to 1 mm. further,
In the case of the C-grooves (c) to (d) and the V-grooves (e) and (f), the joint thickness is increased by increasing the thickness of the welded portion. To fill up the space in the gap, so that welding can be performed without defects.

REFERENCE EXAMPLE 4 FIG. 7 is a perspective view of the opposite side of the rotary tool 1, that is, the back side of the welding surface, in which a support jig 15 for a workpiece 4 having a rotating mechanism is arranged and welded. . The workpiece 4 is fixed to a fixed base 16 and further supports the workpiece on the opposite side of the rotary tool so as not to be deformed by the load of the rotary tool 1. In this case, by providing the support jig 15 with a rotation mechanism, it can be operated with little frictional resistance with the workpiece. Support jig 15
Is linked to the movement of the rotary tool 1 in the welding direction 3 and
It moves in 18 directions while rotating in the direction. The support jig 15 also has a mechanism capable of automatically moving in the up-down direction 19 and the left-right direction 20 following the deformation of the workpiece 4 in the up-down direction or the left-right direction. Butt welding of an aluminum alloy having a length of 20 m, a width of 1 m, and a thickness of 5 mm was performed by a support jig 15 having a mechanism for moving vertically and horizontally in addition to the rotating mechanism. The welding conditions are the same as in Reference Example 1.
By this welding, a high-speed vehicle was manufactured.

In the fourth embodiment, the work is fixed and the rotary tool 1 and the support jig 15 are moved in the welding direction. it can.

Reference Example 5 FIG. 8 shows a sectional view of a method for welding an aluminum alloy for a railway vehicle.

The workpiece in the present reference example has a length of 20 m,
It is an aluminum alloy plate having a thickness of 5 mm and a width of 500 mm. In addition, the height of the joint of the processing member is about 1 mm from other parts.
Is getting higher. The rotary tool 1 is attached to the mobile robot 21 and moves while rotating while being inserted into the welded portion of the processing member 4. In this case, a support jig 15 is arranged on the opposite side of the rotary tool 1. This support jig 15 has at least one of the functions of rotation, up, down, left, and right as in the first embodiment. On the other hand, the processing member 4 is fixed by fixing jigs 22 and 23 from above and below. In addition, this fixing jig 22 is for stably fixing a long processing member.
It has the same rotation mechanism as the support jig 15. The book
In the reference example, the processing member was fixed by the above-described method, and the rotary tool and the support jig were moved to perform welding under the same conditions as in the reference example 1.

FIG. 9 shows a vehicle structure manufactured according to the reference example. FIG. 10 further assembles the vehicle structure of FIG.
1 shows a perspective view of a road vehicle that has been laid. Part of the length of the joint 5 is 1
Although it is 2.5 m, a maximum length of 25 m is formed on both sides, and a railway vehicle is manufactured.

The defect of the welded portion [Configuration of the Invention] to insert the member having the same shape as the cavity (the cavity), again, is welded. In this case, since the member arranged in the hollow portion may move during welding by the rotating tool, it is desirable to fix the member using a roller mechanism in front of the rotating tool.

[0037]

[0038]

[0039]

According to the present invention, the friction welding is performed.
Repairs cavities and enables defect-free friction welding
You.

[Brief description of the drawings]

FIG. 1 is a schematic view of a friction welding method.

FIG. 2 is a diagram showing a defect when a friction weld is viewed from above.

FIG. 3 is a cross section at each position in FIG. 2;

FIG. 4 is a perspective view showing friction welding.

FIG. 5 is a longitudinal sectional view of a friction joint.

FIG. 6 is a longitudinal sectional view showing various types of joints.

FIG. 7 is a perspective view of a friction welding device.

8 is a longitudinal sectional view of a main part of FIG. 7;

FIG. 9 is a perspective view of a structure of a railway vehicle.

FIG. 10 is a perspective view of a vehicle body of a railway vehicle.

[Explanation of symbols]

1: rotating tool, 6, 7, 8: defect, 9a, 9b, 9
c: Repair member.

Continued on the front page (72) Inventor Kinya Aota 794, Higashi-Toyoi, Oji, Kudamatsu-shi, Yamaguchi Prefecture Inside the Kasado Plant of Hitachi, Ltd. In-plant (72) Inventor Yasuo Ishimaru 794, Higashi-Toyoi, Kazamatsu-shi, Yamaguchi Pref. Inspector, Hitachi, Ltd. J. Dawes, An introduction to friction on stil welding and developments, Welding & Metal Fabrication, UK, International Trade Day, Vol. 13-14, 16, NDL accepted on February 13, 1995 (58) Field surveyed (Int. Cl. ⁷ , DB name) B23K 20/12

Claims (2)

(57) [Claims] 1. A method of inserting a rod-shaped rotary tool made of a material substantially harder than a workpiece into a joint of the workpiece and moving the rotary tool while rotating the tool and the workpiece. In a friction welding method using plastic flow due to frictional heat, a defect generated in a weld of the workpiece by friction welding is cut.
Cutting to, the cavity containing the said cutting portion, inserting the insertion member of the cavity portion substantially the same shape, in front of the rotary tool, the rollers the insert member
With the friction welding method
A friction welding method, wherein the insertion member is friction welded . 2. A friction welding apparatus comprising a rod-shaped rotary tool made of a material substantially harder than a workpiece , wherein the rotary tool is inserted into a joint of the workpiece and moved while rotating. Interlocks with the rotating tool in front of the rotating tool
And a roller that moves in the direction of welding progress, and the roller has a cavity formed by cutting a defect in a weld portion of friction welding.
The pressing member presses the insertion member inserted in the portion, and in a state where the roller presses the insertion member,
A friction welding apparatus , wherein a tool friction welds the insertion member .